Polyhydric phenol-acetone-formaldehyde products and process of making same



'w yhydric phenols,

3 UNETE ES PATEN'E QFFECE 2,398,331 POLYHYDRIC PHENOL-ACETONE-FORMAL- DEHYDE PRODUCTS MAKING some AND PROCESS 013 John B. Rust, West Orange, and'Fredei-iclr A. Hessel, Montclair, N. J., asslgnors to Montclair Research Corporation, a corporation of New Jersey No Drawing. Application March 18, 19%, Serial No. 527,140

7 Claims. (Cl. 260-54) This invention relates to heat-hardenable, water-soluble phenolic acetone formaldehyde compositions and the process of making same.

It is an object of this invention to obtain comit positions composed of permanently fusible acetone-formaldehyde condensation products and said compositions being capable of being rendered insoluble and infusible.

It is also an object to prepare compositions conlxf2l= water-soluble acetone-formaldehyde condensation products and a water-soluble polyhydrio phenol which are dissolved in water for use as coating compositions, adhesives, cements, paper and textile sizes, binders for molding coinpositions to produce molded articles, including pressed corh products, and the like. It is also an. object to prepare mixtures of polyhydric phenols and an acetone-formaldehyde condensation product in stable, dry, powdered form and capable of dissolving in water to form heathardenable adhesives and binders.

Still'further objects and advantages of the present invention will appear from the more detailed description set forth below, it being understood that this more detailed description is given by way of illustration and explanation only, and not by way of limitation; since various changes therein may he made by those skilled in the art without departing from the scope and spirit of the present invention.

The preferred acetone-formaldehyde product which may be used according to the process of the present invention is obtained by refluxing one molecular equivalent of acetone and 6 molec- 'ular equivalents of formaldehyde in the presence temperatures either alone or in the presence of alkali, is obtained.

Acetone is the preferred ketone of the present invention, although higher water-soluble ketones may he used, such as methyl ethyl ketone, diethyl ketone and the like as well as diketones, trihetones, etc. Aqueous formaldehyde solutions may be used as well as polymeric formaldehyde.

The nolyhydric phenols of the present invenacid, vegetable tannins such as quebracho, sumac, and the like, resacetophenone, etc. Monolrymic phenols do not produce heat-hardening. compositions. The polyhydric phenols are mixed with g the acetone-formaldehyde condensation product. According to one procedure, the polyhydric phenols are dissolved in the solutions of acetoneformaldehyde condensation products in the cold. These solutions are then added to fillers, are m poured, brushed or dipped, or used as plywood adhesive, impregnant, textile size and the like. Application of heat, or an acid or basic catalyst alone or in combination with heat is necessary to efiect a thorough cure, or hardening ofthe resins. Excellent plywoods have been produced as will hereinafter be described.

Another procedure comprises forming an intimate mixture of the solid polyhydric phenol and acetone-formaldehyde condensation product in 20 dry powdered form. Such mixtures are stable on storage, are in convenient form for shipping and at the time of use are dissolved in water to form a solution which can he used as stated.

Curing or fixing may occur by heating at about 100 C., or more. A mild acid catalyst is preferred although neutral or basic conditions are used as well as salts which give an acid reaction on heating under curing conditions such as ammonium salts of strong acids. v

The amount of polyhydric phenol is not especially critical although about 10% has been found to be satisfactory. Greater or less amounts than 10% may be employed to secure special efiects.

The following examples are given to illustrate the process and products of the present invention. All proportions are in parts by weight.

Example 1.An acetone-formaldehyde syrup was made as follows: 58 parts of acetone, 320 parts of 37% formaldehyde solution and Spar-ts of borax were refluxed together for 6 hours, after which an additional 6 parts of borax were added and refluxing continued for 6 hours. The 80111;- tion'was divided into a number of portions as 4.) follows: 7 Parts A. Acetone-formaldehyde solution 40 Resorcinol 10 Ammonium sulfate.- 1

A clear solution was obtained. It was stable for several weeks, finally forming a stiff gel.

titan-include resorcinol, orclnol, pyrogallol, tannic A clear, stable solution was obtained.

- Parts The two preparations were homogenized and C. Acetone-formaldehyde solution 39 stored at ordinary temperature. A very stable Pyrogallol 1 dry powder was the result. The powders were Ammonium sulfate a. 1 used as aplywood adhesive by dissolving in water A clear solution was obtained. This solution was stable for several. hours.

N Y Parts D. Acetone-formaldehyde solution 39 Pyrogallol A clear solution was obtained which was stable for more than one week.

Parts E. Acetone-formaldehyde solution 30 Tannic acid 6 Ammonium sulfate 0.6

A clear olution was obtained which was stable for several days.

Parts F. Acetone-formaldehyde solution 10 Orcinol 1 Ammonium sulfate 0.2

A clear solution, stable for atleast one week, was obtained.

7 Parts G. Acetone-formaldehyde solution 40 Quebracho powder 10 Ammonium sulfate 1 all of the plywoods with stood 1 hour of boiling without delaminating. The plywood formed from Solution A, Example 1, withstood 6 hours of boiling at-complete immersion, followed by 16 hours to form a 50% solution and applying the solution to wood veneer. The Veneers were dried, pressed together under light screw pressure and heated at 130 C. for 1 hour. A firm resin-bonded plywood was formed which would withstand boiling water. i

We claim:

l. A heat-curable composition comprising a water-soluble polyh drlc phenol having the hydroxyl groups attached to the same aryl nucleus, a water soluble hard acetone-formaldehyde resin formed by reacting 1 moleof acetone with 6 moles of formaldehyde in the presence of borax, and a curing catalyst therefor comprising an ammonium salt of a strong acid, the amount of polyhydric phenol being from about 10% to 100%. based on the acetone resin.

2. A heat-curable composition comprising resorcinol. a water-soluble hard acetone-formaldehyde resin formed by reacting 1 mole of acetone with 6 moles of formaldehyde in the presence of borax, and a curing catalyst therefor comprising an ammonium salt of a strong acid, the amount of resorcinol being from about 10% to 100% based on the acetone resin.

3. A heat-curable composition comprising resorcinol, a Water-soluble hard acetone-formaldehyde resin formed by reacting 1 mole of acetone in water at room temperature, without delaminating even with strong shearing force applied.

Example 3.l0 parts of wood flour wer impregnated with 20 parts of solution A of Example 1. The wet composition wa dried thoroughly and 'discs were molded from the composition at 3000 Parts A. Powdered resin 25 Resorcinol 5 Ammonium chloride 1.25

H Parts B. Powdered resin 10 Resorcinol 10 Ammonium chloride 1 with 6 moles of formaldehyde in the presence of borax, and ammonium sulfate, the amount of res orcinol being from about 10% to 100% based on the acetone resin.

4. A dry powder composition capable of being dissolved in water to form a heat-hardenable adhesive comprising an intimate mixture of (1) a water-soluble polyhydric phenol having the hydroxyl groups attached to the same aryl nu.- cleus, (2) the dehydrated water-soluble hard resinous reaction product of 1 mole of acetone with 6 moles of formaldehyde in the presence of borax, and (3) an ammonium salt of a strong acid, the amount of polyhydric phenol being from about 10% to 100%, based on the acetone resin.

5. A dry powder composition capable of being dissolved in water to form a heat-hardenable adhesive comprising an intimate mixture of (l) resorcinol, (2) the dehydrated water-soluble hard resinous reaction product of 1 mole of acetone with6 moles of formaldehyde in the presence of composition which comprises mixing together a water-soluble polyhydric phenol having the hydroxyl groupsattached to the same aryl nucleus,

' a water-soluble hard resin obtained by reacting 1 mole of acetone with6 moles of formaldehyde in the presence of borax. and a water-soluble curing catalyst which is acidic under heat-cup ing conditions, and heating at between about to C. until hardened, the amount of polyhydric phenol being from about 10% to 100% based on the acetone resin.

'7. The heat-hardened composition of claim 1.

a JOHN B. RUST.

FREDERICK A. HESSEL. 

